the happy customeraND other short storIes From 2011

the happy customerOnce upon a time, there was a steel plant. Inside the plant the warm air was heavy with the sounds of industrial production. Machines and workers labored beneath a curtain of grime. From the shadows a huge ladle crane slowly lifted its massive load of scrap metal to the electric arc furnace. A crushing roar and flash of power transformed the scrap into an orange-hot broth of molten steel. The workers knew that without the service of the monstrous ladle crane, the entire facility would come to a standstill.

One frightful winter night, cold and blustery outside, hot and loud inside, the ladle crane was crippled by the failure of a component in its operating machinery. Over several months the maintenance provider had kept things running but had been unable to make a long-term fix to a recurring problem. The operations manager had recently heard about Konecranes and easily made online contact with the local service branch using a mobile smart phone.

Two days later the plant was in high spirits. Konecranes had responded quickly, then diagnosed and fixed the problem. Over the next several weeks Konecranes performed a variety of service work and offered a number of productivity-enhancing upgrades on the ladle crane and other lifting equipment.

Two months later the customer agreed to a long-term inspection and maintenance contract. Gradually things began to change. Within one year, unplanned downtime had dropped 40%. Fewer safety-related incidents occurred each month. The company became more profitable and invested in additional upgrades that Konecranes had recommended during their Business Review.

Two years later, a second ladle crane is on order. The plant’s maintenance area has two workstation lifting systems. The original ladle crane is running much more reliably after Konecranes used RailQ and CRS to uncover some problems that were not previously known.

The customer is very happy.

The End.

(Note to reader … this story is fictitious, but could be perfectly real. All of the other stories in this booklet are actual events and real customers.)

Mission

Not Just LIFtING thINGs, But eNtIre BusINesses

Vision“We know in real time how millions of lifting devices and machine tools perform. We use this knowledge around the clock to make our customers’ operations safer and more productive.”

ValuesTrust in PeopleWe want to be known for our great people.

Total service CommitmentWe want to be known for always keeping our promises.

sustained ProfitabilityWe want to be known as a financially sound company.

sTraTegies> Differentiation through service

and technology innovation > Lifting people> Global footprint and supply chain> Dual-channel> Real-time information

taBLe oF coNteNtsaerosPaCeTeledyne Technologies, Inc. .............. 7NASA’s Glenn Research Center ......... 8A Leading Aerostructure

Manufacturer ............................. 10

alTernaTiVe energYBrithinee Electric ........................... 11Resort Municipality of Whistler .......12

auToMoTiVeA Midwest Diesel Engine

Manufacturer ............................. 15A Weld Tool Center ......................... 16

general ManuFaCTuringBauer Manufacturing, Inc. .............. 17Link-Belt Construction Equipment

Company, Inc. ............................ 18A Leading Construction Equipment

Manufacturer ............................. 19U.S. Concrete ................................ 20A Leading Construction Equipment

Manufacturer ............................. 21Alaskan Copper & Brass ................ 22Novelis .......................................... 24An Integrated Aluminum Facility ...... 25Westfield Industries ....................... 26Limbach Company ......................... 28

HarBors & sHiPYarDsAPM Terminals ............................... 30

inTerMoDalUnion Pacific Railroad ....................33A Midwest Locomotive Shop ...........34

MiningAn Underground Mining Equipment

Manufacturer ............................. 37A Mining Machinery Company .........38A Mining Equipment Manufacturer .... 39A Leading Mining Manufacturer ......40

oFFsHoreElevating Boats, LLC ......................43National Oilwell Varco ....................44A Southern Manufacturing

Company ...................................46

PoWerBC Hydro, Mica Generating Station ...48R.E. Ginna Nuclear Power Plant ......50

PulP & PaPerLiberty Paper, Inc. ..........................54Weyerhaeuser Paper Mill ................56

sTeelAn Integrated Steel Plant ............... 59Johannessen Trading Company.......60A Leading Steel Company ............... 61EMJ Metals ................................... 62A Leading Steel Manufacturer ........64 A Steel Manufacturing Plant ...........66

For the most current customer stories, go to www.konecranesamericas.com/customerstories

Teledyne Technologies, inc., Huntsville, ala.KNoWLeDGe, commItmeNt aND reLIaBILIty INcrease uptIme aND mINImIze costCHallengerelocation and repairsAlabama-based Teledyne specializes in full-spectrum engineering and advanced manufacturing. It operates in the complex and demanding industries of aerospace, missile defense and nuclear energy, serving both government-supporting and commercial customers.

When faced with a large relocation and repair project, Teledyne Director of Manufacturing Operations, Jeff Holley knew just who to call. “I needed a service partner who could face the challenge, keep the delivery schedule and be capable of handling complex machinery and hardware,“ Holley recalled.

soluTionexpert knowledge of complex partsThe scope of the project included the relocation and repair of small-, medium- and large-sized machines with very sophisticated parts, such as highly precise 5-axis CNC machines. A team of 10-12 Konecranes Machine tool Service (MTS) engineers and specialists was responsible for the three-month relocation project including, but not limited to, new foundations, modernization, material handling, machine installation, debug, alignments and laser calibration.

Due to the complexity of the parts and the special materials and processes used in the Teledyne products, skilled Konecranes personnel were essential in completing this project.

resulTsCompleted on time and within budgetAs a result of proper planning and effective project execution, the relocation and repair project was completed within budget and one week ahead of schedule. Teledyne and Konecranes MTS are currently discussing expanding the cooperation between the two companies. Konecranes MTS Key Account Manager Harold Schoch explains, “We simply want to be viewed as indispensable to our customers’ success.”

“THere Were no surPrises. MTs ClearlY unDersTanDs THe neeDs oF our MaCHines anD giVes a CoMPleTe analYsis anD DeTaileD CosT esTiMaTe.”

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nasa’s glenn research Center, sandusky, ohiouNIQue customIzatIoN saVes customer tIme aND moNeyan arraY oF CHallengesa VarieTY oF soluTionsouter space environment simulation chamber imposes harsh demands on earth-bound metal, lubrication and wiring.At NASA’s Glenn Research Center Plum Brook Station in Sandusky, Ohio, the Space Power Facility (SPF) is home to the world’s largest space environment simulation chamber – 100 feet in diameter by 122 feet high. The dome-capped vacuum chamber is used to test large, space-bound hardware within a simulated environment of outer space.

To hoist, position and stabilize spacecraft components prior to testing, the test chamber is outfitted with a modified polar crane, with the bridge spanning the radius of the area similar to the hands on a clock. Originally built from state-of-the-art systems, controls and materials, numerous upgrades became necessary after nearly 40 years of use.

The extreme negative pressure in the vacuum chamber causes outgassing, a condition where compositional molecules, including dirt, oil and grease, are released from substances present in the vacuum environment. These molecules can stick to the surfaces of spacecraft, which must be kept meticulously clean. The crane is constructed of aluminum, which has very low outgassing properties. Outgassing also affects bearings, wiring and insulation in the control panels, all of which require special materials.

With typical control panel wiring, every time NASA readied the chamber for a vacuum test they would need to remove the entire control panel from the crane—which weighs several thousand pounds. Instead, Konecranes engineers used Teflon® wire, allowing the majority of the controls to remain in place during simulation events.

Certain elements within the control panel, including the inverters, were designed to be removable prior to initiating a vacuum test. Previously, it would take up to several days to remove components with outgassing properties, whereas this new system was designed to enable their removal in a matter of hours.

The original crane system was limited in its ability to provide accurate and precise movements, and had no way to detect whether a load was too heavy or still bolted to a test fixture. This challenge was overcome with the retrofit of a load measuring device integrated with the crane controls.

Because of the sheer size of the spacecraft components being suspended for testing, NASA’s engineering team was keen to gain precise control in making critical positioning adjustments—a function the 1960s technology did not provide. Therefore, Konecranes recommended variable frequency drives, plus enhancements to provide both inching and microspeed functions.

resulTsadvanced technology from Konecranes saves time, enhances safety and improves critical positioning.Selection of new materials and technologies, combined with clever engineering design, saved this important customer time and money, while improving safety and functionality.

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a leading aerostructure ManufacturerKoNecraNes mts DIaGNoseD aND FIxeD a LoNG-staNDING proBLem, reDucING processING tIme By 60% aND saVING $300K per yearCHallengeToo much scrapA leading global manufacturer of aerostructures, located in the southern United States, builds aircraft components such as stringers, ribs and spars for the aerospace industry.

Before Konecranes Machine Tool Service (MTS) was contacted, an old but critical machine in the facility produced an unacceptable quantity of scrap parts, thereby wasting costly raw materials and valuable processing time. Scrap from the machine in question totaled $300,000 the previous year and $160,000 year-to-date.

soluTionupgrade controls, motors and drivesFor over a year and a half, the maintenance department and the original equipment manufacture could not determine what was causing the scrap parts to be created. Konecranes MTS was able to properly identify the problem during the initial visit.

Because Konecranes MTS Service Engineers had proven themselves with a fast response time to a service need, they were awarded a modernization through retrofit. Konecranes compared the machine‘s current performance against matching statistics when it was new, uncovering an unfavorable variance.

Based on the results of this assessment, Konecranes MTS proposed an upgrade with new CNC controls, motors and drives via retrofit.

resulTsless scrap and 60% reduction in processing timeThe Konecranes MTS team has become essential to helping the facility manufacture quality parts and reduce processing time. Konecranes MTS reduced the processing time for some of the components by 60%. In a competitive bid process, the aerostructure manufacturer awarded Konecranes MTS a gantry mill retrofit project.

Brithinee electric, Colton, Calif.INcreaseD craNe capacIty heLps FacILIty meet DemaNDs oF aLterNatIVe eNerGyCHallengeincreased demand, more cranes neededBrithinee Electric in Colton, California specializes in the repair of industrial electric motors and wind generators. They needed additional space and increased crane capacity to work on the large electrical units used in the wind industry, their fastest growing market segment. Brithinee Electric is within 125 miles of two of the largest wind farms in the United States. With demand for alternative energy increasing, the company needed to expand to be able to meet the demand.

In 2004, Brithinee Electric began planning an expansion of their workspace by almost 20,000 square feet.

soluTionKonecranes identifies crane needsBrithinee Electric’s crane selection involved acquiring dimensions for machines they had never seen, including overall dimensions as well as weight. Konecranes helped steer the selection based on cranes generally used in manufacturing plants in the wind industry.

Konecranes developed several different concepts and layouts for Brithinee Electric’s new facility. The two companies and the project engineer worked together to determine the best solution for Brithinee Electric’s needs, including how the geometry of the cranes’ structures (bridge length, dimensions between uprights, etc.) would affect price.

After several collaborative revisions to the plan, Konecranes ended up installing a 20-ton crane, a 10-ton crane, a 5-ton bridge crane and a jib crane.

resulTsProduction levels doubled with new cranesThe larger facility and the new cranes have allowed Brithinee Electric to double its production of wind generator and large motor repair. Konecranes also continues to provide service to Brithinee Electric’s cranes, ensuring increased uptime.

“THe neW BuilDing DeliVereD a WoW FaCTor, anD THe Cranes are a KeY ingreDienT oF THaT.”

Wallace P. Brithinee, Brithinee Electric

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weigh each load it picked up, which helped standardize the product.

According to Patrick Mulholland, Compost Operations Manager at Whistler, another good decision was to let Konecranes Service maintain the crane with quarterly maintenance inspections with a heavy emphasis on preventive measures. “The crane is a sophisticated piece of machinery. We were happy to let Konecranes take care of the crane so that we could focus on other parts of the process.”

resulTsComposting facility receives clear return on investmentWhistler has begun to get a clear picture of their return on investment in the regional composting facility and the crane. The crane reliability has been extremely important to the project.

“Without the crane functioning, the plant does not function. Without the plant functioning, our ability to deal with biosolids locally comes to a complete halt. We have the capacity to receive biosolids for only two to three days before we have to ship it to Washington State at a significant cost,” says Ron Sander, Whistler Environmental Operations Manager.

The benefits of the overhead crane have also included the elimination of diesel fumes in buildings and confined areas, allowing doors to be kept closed and thereby minimizing the escape of odors and dust.

“Whistler is very pleased about the short and long-term benefits our new composter brings,” says Whistler’s Mayor Ken Melamed. “Composting reduces export waste, treats multiple waste streams locally, produces revenue-generating by-products and saves money for the taxpayers and local businesses. The question is why we did wait so long?”

resort Municipality of Whistler, BC, CanadaturNING muNIcIpaL GarBaGe INto marKetaBLe compost WIth aN oVerheaD craNeCHallengeelectric overhead crane needed to move and load compostThe Resort Municipality of Whistler is a community of 14,000 permanent residents whose Whistler 2020 vision for environmental sustainability is one of the most aggressive in North America. Whistler annually welcomes around 2 million guests for winter and summer sports, but due to terrain limitations and a plentiful bear population that rule out a landfill, options for nearby waste disposal are limited.

With exporting its garbage to the state of Washington as the only alternative, Whistler committed to build a new $14 million regional composting facility. Since a prior composting pilot project at a nearby industrial park in Squamish resulted in an odor issue, all planning parties agreed that the material handling methods for the new facility would need to evolve.

One of the major issues identified in the Squamish pilot project was the front-end loaders burning fossil fuel, which resulted in fumes and exhaust inside the building. They also tended to track biosolid residue all over the site, creating a very dirty environment. Therefore, a decision was made to replace them with an overhead crane to move and assemble the primary ingredients for compost.

In addition to sustainability, the crane criteria included best possible reliability, proven technology and the ability to call in local service contacts in case something went wrong.

soluTionFive-tonne bucket, 2.5 m3 grab, DynaPilot anti-sway and automationBased on Konecranes recommendation from Konecranes, a five metric ton bucket crane, operated by electricity, was selected for biosolids handling. The 18-meter operating span with a 2.5 cubic meter hydraulic grab was suitable for a small-scale facility and allowed efficient use of floor space and easy access to all stored materials.

The crane is radio controlled and equipped with DynAPilot anti-sway load control software. It was set up for future automation, though it was decided to have a human running the process, allowing the mixture to be tweaked for changing temperature conditions and pick out unwanted items to maintain quality control in the compost. The crane also had the ability to “THere Were reserVaTions FroM exPerienCeD oPeraTors

on THe Design oF using a Crane raTHer THan loaDers. noW, We’re in agreeMenT THaT iT Has Been ProBaBlY THe MosT PleasanT surPrise oF THe ProjeCT – jusT HoW Well THaT Crane Has WorKeD.”

Ron Sander, Whistler Environmental Operations Manager

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a Midwest Diesel engine Manufacturercut aNNuaL eQuIpmeNt costs IN haLF WIth scheDuLeD INspectIoNsCHallengeProduction demands exceeded capabilitiesA Midwest diesel engine manufacturing plant manufactures diesel engines for consumer pickup trucks. Due to the competitive nature of the diesel engine industry, the company is constantly looking to all areas of production to cut costs and increase efficiencies.

The manufacturing plant was constructed in 1971. It originally built components such as pistons, connecting rods, pulleys, rocker housings and water pumps. In the early ’90s, the plant was converted to an engine production plant. Production demands have escalated ever since.

Like other plants of its kind, it is producing numbers well beyond the plant’s original capacity. Therefore, downtime is not an option.

soluTiona planned approach to repairs, replacements and spare partsThis Midwest diesel engine manufacturing plant has long focused on their core competency–building engines. They have relied on Konecranes to take care of their 120 hoists and cranes for over 15 years. In an effort to extend the life of the plant’s overhead lifting equipment, Konecranes identified the highest usage cranes and set up a maintenance plan for the cranes selected.

The plan included replacing out-dated equipment, rebuilding older “work-horse” hoists and establishing a structure for repairs. This allowed for repairs to be completed as they were identified during inspections, eliminating potential downtime from unexpected breakdowns.

resulTsPer unit cost decreased 50%, excellent safety recordBy collaborating with Konecranes and sharing expertise, the annual cost per unit has decreased 50% from 2005-2009 with no additional downtime. Since this maintenance plan has been put into effect, there have not been any crane-related injuries or incidents at this manufacturing plant.

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a Weld Tool CentercompreheNsIVe preVeNtIVe maINteNaNce pLaN puts customer at easeCHallengein-house maintenance unable to meet demandIn the Midwest, a weld tool center for a major automobile company engineers the robotic weld tools that assemble the body structure of a vehicle. Over 200 cranes are used at this facility, from 1-ton chain hoists to 50-ton cranes, as well as jib and gantry cranes.

The in-house maintenance team was overwhelmed with the crane service needs of the facility. Because service and repairs were not performed consistently, the maintenance records were not kept up-to-date. The weld tool center needed a company capable of providing service and preventive maintenance for all of their cranes.

soluTionMaintenance outsourced to KonecranesOut of several competing offers, Konecranes stood out as the clear choice to be the sole provider for crane maintenance. The company has outsourced 100% of their crane work to Konecranes. The cranes have been repaired and now are performing up to standard. Quarterly and annual inspections help to proactively determine problems before they happen, and monthly preventive maintenance helps keep the cranes in top condition.

A technician is on site five days a week to do repairs and cover breakdowns. With a strong maintenance team to depend on, the in-house maintenance team no longer needs to track crane inspections, repairs, breakdowns or expenditures.

resulTsKonecranes Circle of Compliance in place, satisfied customer purchased eight more cranesThe customer continues to follow the business plan and benefit from the Circle of Compliance – to inspect, repair and maintain.

Based on the successful relationship between the companies, a sister plant recently purchased eight new cranes from Konecranes.

Bauer Manufacturing, inc., Conroe, TexascustomIzeD aND reLIaBLe proDuct DesIGN puts customer at easeCHallengegrowing company requires more cranesBauer Manufacturing, Inc. is an international provider of services, machinery and ancillary products in the earth-working and groundwater fields, operating under three industry segments including construction, equipment and resources.

Based in Germany, this 200 year-old company expanded to North America in 2008. Bauer’s first manufacturing headquarters in North America is located in the Conroe Industrial Park in Conroe, Texas. The campus sits on 80 acres and is being built in phases.

The first phase is over 200,000 square feet. When Bauer started to design and build phase one, they turned to Konecranes for their overhead lifting needs.

soluTionKonecranes provides specialty lifting equipmentKonecranes was chosen as the provider of Bauer’s eight overhead cranes and two Rubber Tire Gantry cranes. Konecranes offers state-of-the-art, high quality products at competitive prices. Because of their price competitiveness and their follow up with sales and service, they were awarded the job.

Bauer had specific needs for the use of the cranes. Konecranes was able to work with upper management to design cranes that would fit their needs.

resulTsQuality products and service satisfy the customerBauer Manufacturing is very pleased with Konecranes and the sales and service team. With the expansion of Bauer Manufacturing in North America, there are plans to install many more Konecranes products in other facilities in the near future.

“We Feel CoMForTaBle THaT our KoneCranes Cranes Will giVe us gooD serViCe Well inTo THe FuTure.”

Bauer Manufacturing

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link-Belt Construction equipment Company, inc., lexington, Ky.Deep expertIse resuLts IN a WIN-WIN sItuatIoNCHallengeincreased production levels call for machine upgrades and modernizationsThe Link-Belt Construction Equipment Company is a leader in the design, manufacture and sales of telescopic and lattice boom cranes. Their headquarters are in Lexington, Ky.

Link-Belt’s core production base and center for worldwide operations is its 500,000 sq. ft. manufacturing facility.

To support their expansion plans over the last 10 years, Link-Belt brought in Konecranes Machine Tool Service (MTS) to provide technical assistance and expertise to solve their machine challenges.

soluTionModernizations performed on diverse machinesIn years past, Konecranes MTS had provided many solutions to Link-Belt’s machine challenges. Their large Cincinnati-Gilbert Floor Mills were mechanically overhauled and retrofitted with a Fanuc control system. “The personal delivery of the Mitsubishi special head spindle was appreciated. You felt this urgency as if you were in my shoes here,” said Bowman to Harold Schoch, Key Account Manager of Konecranes MTS.

Konecranes MTS performed a complete geometry overhaul of a Giddings & Lewis 60, the full contouring table rebuild of a Cincinnati T-40 HBM and the complete restructure of the long “X” axis on a smaller Cincinnati-Gilbert boring mill as well.

“Your help with our Cincinnati-Milacron, the recent help with the double gantry boring mill head, the Giddings & Lewis 60 and the Wotan Cutmax 2 have proven to Link-Belt Senior Management that your staff can work on diversified machining equipment without concern,” Bowman commented.

resulTsCompleted on time and within budget“Konecranes MTS continued commitment to quality, attention to meeting the customer’s deadlines and coming in on budget continues to make your company the first in mind when support is needed on our machine tools,” continued Bowan.

“THis CinCinnaTi-gilBerT MaCHine Has WorKeD Well For us anD Was an exaMPle oF Your TeaM’s exPerTise.”

Link-Belt Construction Equipment Company, Inc.

a leading Construction equipment ManufacturerremaNuFactureD machINe INcreases uptIme aND proDuctIVIty WhILe eNhaNcING saFetyCHallengeincreased demand called for a new machineA leading construction equipment manufacturer produces parts and components for construction and power generating equipment. Their production process requires special machine tools for facing pockets. These “pocket facing” machine tools are used to cut the smooth, flat surfaces where the bearings for planetary gears are mounted. Market demand increased beyond the capacity of their critical path machine tools. They sought a qualified machine tool service team to identify a used machine tool that could be redesigned and modified to produce the proper part accuracies and finishes required for pocket facing applications.

soluTiona refurbished machine met the challengeWith the experience of rebuilding, remanufacturing and retrofitting over 170 machine tools for this construction equipment manufacturer, Konecranes Machine Tool Service (MTS) had the technical expertise necessary for the project. After a careful review and thorough inspection, a used vertical machine with a pallet changer was chosen. The pallet changer reduced overall set-up time as parts could be put on the fixture of one pallet while the machine was cutting a different part on another pallet.

A customized head was added to generate the pocket facing cuts. Due to the fixture height and the size of the generating heads required for the part, a riser was designed and installed underneath the machine’s column in order to provide enough height for machining the part. The gib and clamping system of the machine was re-engineered to increase the machine’s strength, dampen vibrations and make it easier to perform maintenance work.

A new chip collection and conveyor system with guarding was installed to protect the machine and further reduce the overall maintenance needs for the machine. A full enclosure that included door safety interlocks, that was not incorporated on the original machines, was designed to further enhance operator safety.

resulTsenhanced part accuracies, safety and productivityThe machine run off tests showed that the remanufactured machine was capable of providing the part accuracies and finishes required for pocket facing applications while enhancing safety and productivity.

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u.s. Concrete, san Diego, Calif.customIzeD INstaLLatIoN, DecreaseD coNstructIoN costs aND INcreaseD capacItyCHallengeDesigning a new facilityU.S. Concrete serves the construction industry with concrete and precast/ prestressed concrete products.

As a satisfied customer of Konecranes for over 10 years, there was no question whom they would turn to when they were building a new plant. “We wanted a design that was efficient, well laid out, on time, and of course offered value overall,“ said Todd Ebbert of U.S. Concrete. “Before we settled on this new facility, we looked at different options at existing sites and Konecranes helped us design and configure various options for each one.”

soluTionCustomized cranes and layout assistanceThe new facility would be built on an 18-acre site. The precast concrete manufacturing would be performed in an 80,000 sq. ft. building. The facility was designed for two large crane bays. These crane bays would be served by 10 total overhead bridge cranes with capacities ranging from 5- to 50-ton.

It was a concern that the building walls would not be able to support the largest crane’s full capacity of 50-ton. Konecranes suggested that the center 40’ span of the 80’ bridge crane would lift the full capacity of 50-ton while the outer 20’ of the span to either side would be limited to 30-ton capacity. This effectively reduced the load on the walls, and in addition, decreased construction costs. Konecranes provided technical support as well as innovative ideas to keep the project cost-effective while meeting all of the customer‘s needs. Two cranes from the old facility were brought to the new site. Konecranes modified these cranes to meet the new facility requirements.

resulTsCustomer pleased with crane system and performanceThe facility as well as the crane runway system were built to schedule and completed from start to finish in less than a year. “The crane system has performed exactly as expected and we are very pleased with the results. We have converted a couple of the cranes to wireless pendants and may convert all of them in the near future,” said Ebbert.

a leading Construction equipment ManufacturerQuaLIty parts aND precIse eNGINeerING eLImINate DoWNtImeCHallengeQuality and productivityIn the Midwest, a leading construction equipment manufacturer produces medium speed diesel engines for electric power, locomotive and industrial applications. As an integral part of the manufacturing process, machine tools are used to bore holes and provide smooth finishes to the engines.

One of their critical machine tools contained outdated controls, motors and drive amplifiers. The aged components caused control-related failures that stalled production at the facility. Every moment the critical machine remained out of service cost the facility expensive amounts of downtime. The machine needed to be updated with more reliable components in order to meet projected demands.

soluTionCollaborative repairs with the oeMA collaborative effort was needed to ensure the best results in the shortest amount of time. The construction equipment manufacturer needed a supplier with a comprehensive range of technical experience that could effectively work in concert with the original equipment manufacturer (OEM) and the in-house repair team to make the necessary repairs and improvements.

Konecranes Machine Tool Service (MTS) was selected due to their unique skill sets and access to a comprehensive supply chain for spare parts. Konecranes MTS calibration technicians were able to optimize the machine’s geometry and positioning using Hamar and Renishaw laser systems.

resulTsDowntime brought under control, quality increasedKonecranes MTS Service Engineers eliminated the downtime caused by the aged machine tool components. The mechanical and geometrical repairs that Konecranes MTS made increased the quality of parts the facility produces. The collaborative effort with the in-house repair team and the OEM decreased the amount of time required for the machine to be put back into production. Based on the success of this project, Konecranes MTS will continue to work alongside the customer on all future shutdown projects.

“our long TerM relaTionsHiP WiTH KoneCranes Has BeneFiTTeD us WiTH THe laTesT aDVanCes in TeCHnologiCal anD saFeTY asPeCTs For our liFTing reQuireMenTs.’’

Todd Ebbert of U.S. Concrete

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alaskan Copper & Brass, Kent, Wash.KoNecraNes cxt craNes aND maINmaN® INspectIoNs reDuce maINteNaNce costs By 60%CHallengeTaking old cranes to a new locationAlaskan Copper & Brass Co. was moving a large part of its operation from Seattle and Renton to a facility in Kent, Wash. The company needed new lifting equipment and also wanted to relocate some older cranes at the Renton facility, not purchased from Konecranes. Alaskan Copper owned a total of 138 cranes as well as about 50 different types of under-hook devices. Most of them were being maintained in a reactive mode, with repairs occurring only when something stopped working.

soluTionsome cranes relocated, others purchased new, all maintained with MainMan®In Phase I of this operation, Alaskan Copper purchased two 5-ton single-girder CXT cranes from Konecranes and asked Konecranes to remove four older cranes from the Renton facility, modify them and move them to Kent. This process went well, and Eagle Hilton, Alaskan Copper’s new mechanical project coordinator, retained Konecranes to begin monthly inspections of all of its cranes using MAINMAN®, a multi-point visual inspection. MAINMAN® inspection captures data on the condition of over 225 crane components and then analyzes, prioritizes and schedules required repairs in compliance with local statutes and laws.

In Phase II, Alaskan Copper purchased four more 5-ton double-girder CXT cranes, and also asked Konecranes to provide and install over 700 ft. of runway for the new cranes in an existing building. The configuration of the long bay runway allowed offloading of product into smaller bays running perpendicular to the runway.

resulTseffective sharing of responsibility with in-house teams, maintenance costs down 60%When the inspection program began, Konecranes technicians were working on the older cranes weekly. But one year later, as larger issues revealed by the inspections were resolved, Konecranes inspects just 15-18 cranes

a month on a regular schedule. A parallel program for inspecting the under-hook devices has also been implemented. Konecranes takes care of significant repairs, while minor issues are handled in-house.

“In the first year, we spent a good bit of money resolving long-term problems with the older cranes, but since then our maintenance costs have gone down by around 60%,” says Eagle Hilton. “The biggest benefit is that downtime, and significant breakdowns have been drastically reduced. Now, we prefer to maintain equipment at more optimum levels. With our new policy of outsourcing of maintenance for critical equipment like forklifts and cranes, we’re down to one in-house electrician at this facility.”

“We are TrulY saTisFieD WiTH eVerY asPeCT oF serViCe We’Ve reCeiVeD FroM KoneCranes. CoMPanies liKe Yours MaKe CoMPanies liKe ours BeTTer anD sTronger, noT To MenTion MaKing MY joB a loT easier.”

Eagle Hilton, Mechanical Project Coordinator, Alaskan Copper

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novelis, oswego, n.Y.hIGh QuaLIty, cost eFFectIVe proDuct INcreases proDuctIVItyCHallengeunreliable radio controls stall productionNovelis, in Oswego, N.Y., is the global leader in aluminum and beverage can recycling. They produce an estimated 19% of the world’s flat-rolled aluminum. Cranes are a critical part of the rolling, casting and fusing manufacturing processes and are used to transport sheets of aluminum.

The radio control systems they used to operate their cranes began to malfunction. Without a reliable way to maneuver their cranes, the manufacturing process stalled, resulting in expensive downtime.

soluTioneffective radio controls allow operators to be mobile, productive and efficientOut of two other proposals, the Cervis/Ikusi Hand Held and Belly Belt radio controls proposed by Konecranes stood apart as the highest quality products at the most cost- effective price. The controls have a heavy duty customized transmitter, a category level 3 safety rating, long battery life, fast chargers and position selector switches that either maintain position or force return to the 0 position, which allow operators to be safe, mobile, productive and efficient.

The first few radio controls that were installed worked effectively and did not cause downtime. Since then, over 75% of the plant’s cranes have been switched over to Cervis/Ikusi radio controls.

resulTsadditional smart solutions added over timeAfter proving themselves with the radio control project a decade ago, Novellis trusted Konecranes to increase their productivity in other areas. Currently, Konecranes is developing an anti-collision system for two levels of cranes – one crane on the high bay and two cranes on the lower bay. The cranes will coordinate their positions use Smart Solutions technology, which helps prevent collisions.

The anti-collision system ensures that the crane on the high bay will not go over the cranes in the lower bay while holding a load. Smart Solutions Anti-Sway technology is being added to three of their cranes. By preventing the load from swinging during crane travel, the operator does not have to divide their attention from controlling the crane movements and monitoring the load itself.

an integrated aluminum FacilitypreVeNtIVe maINteNaNce saVes oVer $45K usD IN repaIrs aNNuaLLyCHallengeno challenge yet ... Konecranes keeping in touch with a potential customerAn integrated aluminum and smelting facility, located on the east coast, is one of the longest continually operating aluminum facilities in the world. Its products serve the automotive, industrial, and aerospace industries. Their cranes range in size from 10-50 tons and are used to handle molten metal and to transport the finished product.

Seven years ago, the integrated aluminum facility handled all crane maintenance work internally. After three years of contacting the company, Konecranes was able to arrange a meeting to discuss benefits of the MAINMAN® preventive maintenance program. They liked the idea of a proactive plan for inspections, repairs and maintenance, but because they had an in-house crane maintenance team, they did not have a need for it at that time.

soluTionan occasion to inspect revealed numerous opportunities for repairThe next year, the integrated aluminum facility called Konecranes with an urgent need for a complete inspection to be performed on one of their cranes. Many of their other cranes were experiencing frequent breakdowns as well. The technicians completed the emergency inspection and submitted a comprehensive MAINMAN® report which included a detailed assessment of the crane. The integrated aluminum facility was so impressed with the crew and the quality of their work that they turned over 15 more of their cranes for the same process. The inspections showed that many cranes were not up to code. Konecranes was asked to complete all of the repairs in a process that took two years to complete.

resulTsoverall savings of $45,000 per yearAfter the extensive repair process, the cranes are in better overall condition. Konecranes has an annual contract for inspections and planned maintenance. The amount of downtime and unplanned repairs has decreased significantly at the plant. The integrated aluminum facility now saves over $45,000 USD annually in inspection and preventive maintenance costs compared to prior years. Konecranes also performs preventive maintenance and has a site contract on all of the below-the-hook devises at other areas of the work site.

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Westfield industries, Manitoba, CanadamaNuFacturING capaBILIty aND specIaL INstaLLatIoN meets coNstructIoN DeaDLINe CHallengenew plant needed open plan and space flexibilityWestfield Industries has been manufacturing grain augurs for over 50 years. Their simple, straightforward design, ease of operation and labor-saving performance have made Westfield the number one portable grain augur manufacturer in the world. This success spurred development of a new manufacturing facility near Winnipeg. Westfield’s design team wanted a completely open span inside the building for maximum flexibility.

Westfield didn’t want machines permanently sited anywhere—they wanted to be able to reposition equipment as needed as augur designs evolved. For that to work, they required two new cranes that could span the entire building. Manitoba-area lifting suppliers were unable to provide a cost-effective solution for the cranes with the 105-foot span the design called for, as their facilities were not set up to be able to manufacture the large and long box girders required. Westfield was faced with the possibility of having to split the shop into two 52’ sections and install a third, central runway with cranes on each side of the building.

soluTion3-ton double girder cranes with 105-ft spanWestfield’s Process and Quality Engineering Manager Brian Wilcox contacted Konecranes for a proposal on two 3-ton CMAA class C CXT double girder cranes with a 105-foot span. Not only was Konecranes able to manufacture the cranes with exceptionally large and long girders in their Edmonton factory, they were also unfazed by a demanding construction schedule. Westfield had only a short window of opportunity to complete the building before the rainy season and could not leave

the roof open for a traditional, straightforward install. Konecranes was responsible for taking the measurements and forging a plan to install the 105’-long girders after the building was closed in.

resulTsCustomer satisfied with “flawless” installationKonecranes was not only responsible for installation, they also took care of all of the challenges of transporting the two 105-foot cranes from Edmonton using a special bogie wheel arrangement on a highway tractor trailer rig. According to Wilcox, everything went according to plan. “We had a great relationship, and the project worked out very well. We had a good thing going with the installation—it went flawlessly.”

“KoneCranes Was MuCH More ProFessional THan THe oTHer BiDDers anD gaVe us ConFiDenCe THeY CoulD aCHieVe our goals.”

Brian Wilcox, Process and Quality Engineering Manager

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limbach Company, laurel, Md.custom INstaLLatIoN oF cxt craNes aND ruNWay smooths traNsItIoN For customerCHallengestrict time schedule to install cranes and runwayThe Limbach Company was moving into a new building specifically tailored for its specialty piping business in the Washington D.C. metro area, and time was of the essence. Limbach’s capabilities include HVAC piping and plumbing, stainless steel specialty piping, design build and energy retrofit/management systems.

Limbach planners needed two new cranes and a new runway, and planned to move one of their existing 5-ton cranes into the new facility. All the cranes and new runway had to be installed during several specific time windows in order to be in sync with the completion of the rest of the building.

soluTionsuccessful and timely installation working around other tradesLimbach’s Trade Manager Robert Davis contacted Konecranes for a proposal on two 2-ton CXT cranes, relocation of the existing 5-ton crane and engineering and installation of 240 feet of runway. “Our timeframe put them in a bit of a pickle because our construction people were installing drywall while Konecranes was building the runway,” says Davis. “However, everything went off without any problems whatsoever. Those guys did a tremendous job and were just very professional. Things went so well that I would recommend them to anyone looking for an overhead crane.”

resulTsexcellent crane performance enhances productivityA year later, Davis is still pleased with his CXT cranes, which have given him “no trouble at all.” Both of the cranes are performing exactly as promised. The impressive list of operating benefits that they deliver includes improved rope life, and fast, accurate load positioning. And, the reduced hook dimensions create more usable workspace. Compared to older hoist designs, CXT cranes can operate closer to walls and lift loads higher. For new facilities like Limbach’s, CXT improves flexibility for factory layout and material flow planning, and enables use of a smaller building shell that is less expensive to build.

“We aPPreCiaTe HaVing a suBConTraCTor THaT PerForMeD as Well as KoneCranes DiD. iT Was a PosiTiVe anD enjoYaBle exPerienCe For us.”

Robert Davis, Trade Manager, Limbach Company LLC

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aPM Terminals, elizabeth, n.j.curreNt aND poteNtIaL repaIrs IDeNtIFIeD to Keep port craNes up aND ruNNINGCHallengeMore complete crane analysis neededNearly 4,500 containers a day pass through the gates at APM Terminal’s 380-acre Port Elizabeth facility in Elizabeth, N.J. The terminal processes anywhere from 550,000 to 763,000 tons of containerized cargo annually. To handle the transfer of these massive containers from ship-to-shore and back, the facility built a fleet of 30 Rubber Tire Gantry (RTG) cranes from Konecranes.

APM facilities are required by OSHA Maritime regulations to have an OSHA-certified inspector examine their cranes annually. However, the basic safety check performed in compliance with OSHA did not provide the Port Elizabeth facility with sufficient critical information about the mechanical, structural, and electrical aspects of each RTG crane.

soluTionComprehensive MainMan® inspections With each RTG crane costing nearly $1.5 million, the Port Elizabeth facility chose to invest in Konecranes MAINMAN® inspection services to help prolong the lifespan of each crane and maximize their investment. The OSHA inspection takes one technician about 1.5 hours per crane to complete. Konecranes MAINMAN® inspection takes three technicians working eight hours per crane to complete.

That translates into a team of 15 Konecranes inspectors working on-site for up to three weeks. MAINMAN® requires a substantial amount of time because they capture data on the condition of more than 225 crane components. Konecranes certified inspectors evaluate hundreds of component parts and draw on thousands of hours of training and experience to analyze wear patterns. The results include a detailed

analysis of each crane, repair priorities, and a suggested schedule of required repairs in compliance with local statutes and laws.

resulTsPreventive maintenance saves time and reduces warranty workBecause of the MAINMAN® inspections, APM has found that they rarely have to call Konecranes for warranty work or troubleshooting. Instead, they use the crane summary reports as a guideline for their maintenance crew to use in mapping out their workload.

“We have 30 mechanics to look over 32 RTGs, 19 top loaders, 10 empty handlers, payloaders, snow removal equipment, manlifts, and large forklifts,” APM says. “It works out to be about two machines per man, so we always keep busy. We don’t have the time to do the fine-tooth comb inspections that Konecranes does for us.”

In addition to saving time, the inspections have also caught small issues and brought them to the maintenance manager’s attention before they became major problems.

“iT saVes us TiMe BeCause We Do PreVenTiVe MainTenanCe CHeCKs on THe MaCHines BaseD on KoneCranes reCoMMenDaTions.”

APM Terminals

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union Pacific railroad, north Platte, neb.preVeNtIVe maINteNaNce aND INspectIoNs LeaD to totaL cost saVINGsCHallengeunreliable crane performanceUnion Pacific Railroad (UPRR) helps link production and consumption points in the U.S., and across the world, with a network to deliver the energy, food, raw materials, durable and consumer goods to support the nation’s growth.

The North Platte shop inspects, repairs and/or provides maintenance to UPRR locomotives 24 hours per day, seven days per week. Services include: change outs of power assemblies, traction motors, alternators, turbos, engine blowers and electrical equipment. They can perform these services on 12 locomotives at one time. North Platte averages six complete extensive locomotive inspections per week. Their eight critical cranes, a variety of underhung and top running cranes ranging from 5-20 ton capacities, provide lifting assistance for major locomotive components during the repair and maintenance process of the cranes.

Due to a lack of standardized inspection practices, timing and content of inspections were inconsistent which resulted in unacceptable levels of crane reliability and safety standards.

soluTioninspections, preventive maintenance and modernizations Konecranes provided and continues to provide a standardized monthly crane inspection/preventive maintenance program to ensure the equipment operates in both a safe and reliable manner. Konecranes inspectors and UPRR maintenance staff work in partnership to identify safety/productivity issues and create repair plans to eliminate deficiencies in a timely manner.

In addition, modernization recommendations are presented, when applicable, to increase the ergonomics for crane operators, speed up processes that require the use of the cranes and enhance the level of safety when the cranes are in use.

resulTsover 60% reduction in crane repair costAs a direct result of Konecranes inspection/preventive maintenance partnership, the North Platte shop realized a 62% reduction in emergency repair costs and 64% reduction in planned repair cost from 2009 to 2010. Improved crane uptime led to total maintenance cost savings.

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a Midwest locomotive shopexteND eQuIpmeNt LIFe aND eNhaNce saFety WIth eQuIpmeNt INspectIoNs CHallengeunmarked equipment fails to meet safety requirementsThis Midwest locomotive shop helps link production and consumption points in the U.S. with a network to deliver energy, food, raw materials and consumer goods to support the nation’s growth.

The shop inspects, repairs and provides maintenance to locomotives 24 hours per day, seven days a week. Services include: change-outs of power assemblies, traction motors, alternators, turbos, engine blowers and electrical equipment. On average, they complete six extensive locomotive inspections per week. Their eight critical cranes provide lifting assistance for major locomotive components during the repair and maintenance process of the locomotives.

This particular shop has an abundance of below-the-hook lifting devices that were manufactured either in-house or are very old. These devices did not meet OSHA and ASME requirements due to a lack of capacity markings. Due to their age, the material integrity of each unit was also in question.

soluTionCapacity levels determined with engineering study and nDT testingTwo requirements from OSHA and ASME needed to be met, OSHA 1926.251(a)(4) and ASME B30.20.

OSHA 1926.251(a)(4) stipulates that special custom design grabs, hooks, clamps or other lifting accessories, shall be marked to indicate the safe working loads and shall be proof-tested to 125% of their rated load prior to use.

In addition to displaying the rated load, ASME B30.20 requires the manufacturer’s name (or contractor’s name if fabricated on-site) and lifting device weight for items over 100 pounds be displayed on structural and mechanical below-the-hook lifting devices.

To meet these requirements and thereby improve safety, Konecranes performed an engineering study to determine the capacity of each unit and marked each accordingly. In addition, non-destructive testing was provided to ensure material integrity.

resulTsregulations are met, improving safety and reducing equipment overloadOSHA and ASME regulations have been met due to marking each piece of equipment with the appropriate capacity rating, manufacturer and device weight as needed. Due to the new markings and material integrity testing, overloading of the below-the-hook devices decreased, raising the level of safety within the shop.

Of critical importance, a tailored inspection program was developed to enhance safe operation of these units for everyday use and meet additional inspection guidelines called for in ASME B30.20. Along with creating a proactive safety environment, the inspection program may extend the life span of the equipment now that appropriate capacity loads are taken into account.

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an underground Mining equipment ManufacturerKoNecraNes mts WorKs oVertIme to FINIsh repaIr WeeKs aheaD oF scheDuLeCHallengeCritical machine tool breaks downAn underground mining equipment manufacturer, located in the western United States, is a worldwide leader in high-productivity mining equipment. Machine tools are essential components in their production line.

One day, a breakdown of a critical path machine tool, a Horizontal Boring Mill (HBM), delayed processes down the line. Every day the machine tool was down had a major impact on parts production, which created a company-wide problem.

The original equipment manufacturer (OEM) started emergency repair services on the HBM, but was not able to complete them. The mining equipment manufacturer needed a quick turnaround in order to meet their customer’s demands for parts.

soluTionrepair completed—two weeks ahead of scheduleBecause of the comprehensive familiarity Konecranes Machine Tool Service (MTS) had with this particular machine, both electrically and mechanically, Konecranes was the ideal choice for the project. Konecranes MTS was contacted and a qualified service engineer was dispatched immediately to evaluate, repair and rebuild the machine. The Engineer worked through weekends to satisfy the customer and the machine was back into production in record time—two weeks ahead of schedule.

resulTsTrusted partner for the futureThe underground mining equipment manufacturer has scheduled Konecranes MTS for several modernization projects since that emergency repair. They continue to contact Konecranes MTS as service or preventive maintenance needs arise.

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a Mining equipment ManufactureraDVaNceD machINe moDerNIzatIoN DecreaseD DoWNtIme aND set up tIme WhILe INcreasING oVeraLL eFFIcIeNcyCHallengeaged equipment and high maintenance costsA mining equipment manufacturer uses sophisticated machine tools to manufacture products for the underground mining industry. A critical machine tool experienced downtime due to aged machine tool components. They needed a qualified machine tool service team to modernize the Giddings and Lewis Horizontal Boring Mill (G&L HBM) in order to minimize downtime and reduce maintenance expenses.

soluTionMachine redesign and rebuildKonecranes Machine Tool Service (MTS) was selected to modernize the G&L HBM. The modernization project involved a complete redesign of the spindle carrier. The aged planetary hydraulic gear box was removed and replaced with a two-speed planetary gearbox system which simplified the headstock with fewer wear parts. The new design eliminated the need to replace the hydraulic valves and gears at a high price and a long lead time.

A digital spindle drive system was integrated with the latest Fanuc CNC control system. The new CNC control system gave the facility the flexibility to control the spindle speeds between minimum and maximum available RPM when adjusting the stock removal. Konecranes developed a customized control pendant equipped with an LCD screen which enhanced safety by allowing the operator to have closer access to the parts they set up.

resulTsreduced cost and downtime, increased throughputThe Giddings and Lewis HBM modernization decreased downtime while increasing throughput and efficiency. Maintenance costs were greatly reduced. Konecranes will continue to perform preventive maintenance, calibration and service support.

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a Mining Machinery CompanyprecIsIoN caLIBrateD machINe achIeVes hIGhest LeVeL oF accuracyCHallengestruggling with tight toleranceA mining machinery company uses sophisticated machine tools to manufacture and repair products for the mining industry. One of their Cincinnati Gilbert Horizontal Boring Mills (HBM) was struggling to perform tight tolerance work. Because of Konecranes Machine Tool Service’s (MTS) experience with this equipment, they were able to use their preventive maintenance program to evaluate the situation, review findings in real time, make the necessary adjustments and confirm the results.

soluTionassessment and re-calibrationFor the Cincinnati Gilbert HBM, Konecranes MTS performed a complete assessment of the machine’s geometrical condition. Then, MTS service engineers used Mahr Federal electronic levels to precision level the machine to exceed the original manufacturer’s specifications for pitch and roll.

Konecranes MTS state of the art Renishaw ML10 interferometer laser system was used to calibrate the positioning accuracy of the machine. After the machine had been precision leveled and laser calibrated and a Renishaw ballbar had been run to confirm the results, the mining machinery company was able to confirm with their coordinate measuring machine substantial improvements in their product’s quality.

resulTsHighest ever level of accuracy, beyond original specificationsAfter Konecranes MTS optimized the Cincinnati Gilbert HBM, it performed at the highest level of accuracy ever achieved in its lifetime. The improved machine repeatability and accuracy reduced set up time for parts by minimizing the necessary adjustments to accommodate the machine’s geometry issues.

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a leading Mining Manufacturer operator traINING ImproVes saFety, preVeNts eQuIpmeNt DamaGe at a Gypsum QuarryCHallengeFrequent breakdowns from suspected improper useA leading manufacturer of gypsum wallboard operates a quarry in North America. The quarry processes up to 20,000 tons of rock per day, which is extremely hard on material handling equipment.

The mine uses a fleet of 10-ton overhead cranes to maintain large transfer trucks and other mining equipment. They had frequent crane breakdowns and experienced problems with ropes being pulled off the drums when the loads were too heavy for the cranes, allegedly from improper operator use. Only a few of their cranes had load limiters installed. Purchasing higher-capacity equipment was not an economical option.

soluTionrFQ for maintenance led to operator training as the fixThe mine began looking at outsourcing crane inspections and maintenance. An analysis of contractors based on a formula comparing rates, documentation, competency of technicians and other factors revealed Konecranes as the leading supplier. The relationship began with Konecranes providing inspections only, with the mine performing repairs and maintenance on the items Konecranes identified.

After seeing the recurring damage caused by operators attempting to lift loads too heavy for the equipment, Konecranes recommended that they implement a mandatory crane operator safety training program. Going back to the equipment manuals, Konecranes showed operators how to break down the trucks into elements weighing 10 tons or less , sections that the equipment could handle. The safety training program showed the operators the basic methods of calculating the weight of identified sections.

resulTsoperator training + new cranes = long term relationshipThe success of the operator training program in reducing equipment damage led to Konecranes having contracts for virtually all of the customer’s crane maintenance needs. The mine also began purchasing new-generation Konecranes CXT cranes with variable speed bridge and trolley motions and built-in load limiting devices to replace older cranes. The numerous safety and low-maintenance features of the CXT were an excellent fit for the mine, where reducing maintenance expenses is a prime objective.

According to the mine’s maintenance planner, the training program has made all the difference. Now, every crane operator must complete the crane operator safety course in order to operate a crane at the facility. Konecranes has become a valued contributor toward improving the mine’s safety and production.

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elevating Boats, llC, Braithwaite, la.aDVaNceD machINe restoratIoN eNhaNces saFety aND ImproVes ease oF useCHallengeCritical machine damaged by Hurricane KatrinaElevating Boats (EBI), LLC in Braithwaite, La. uses machine tools to manufacture offshore lift boats, pedestal cranes, hydraulic cylinders and many other mechanical and hydraulic components for the global boating industry. Machine tools are essential in manufacturing their products and components.

In 2005, a highly-specialized vertical boring mill (VBM) was damaged in Hurricane Katrina. As a core machine to the EBI product line, the loss of this machine reduced their capacity to meet the demands of their customers.

Three proposals were generated for this project. Konecranes MTS was chosen based on having the best value proposition because Konecranes employed the most talented technological team, with experts in every area required for the project. The plant manager at EBI had worked with other retrofitters in the past, but he did not believe that they had enough mechanical expertise to retrofit this machine.

soluTionKonecranes MTs retrofits machine, adding safety featuresKonecranes MTS performed a complete retrofit of the machine. An advanced feature was added which allowed for a more dependable location of the movable rail through a process called synchronous axis control. This improvement enhanced safety and made the machine easier to operate. An additional enclosure was added for safety.

resulTsThe machine is completely restored, with added featuresThe machine was restored to its original geometry and positioning specifications. The updates allowed the operator more flexibility for assembling complex parts. Because of the project success, Konecranes MTS is the favored supplier to rebuild and retrofit another machine.

after

Before

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national oilwell Varco, Houston, TexaseNhaNcING saFety WIth craNe operator traINING courseCHallengeCrane operators need training supportWhen industry leader National Oilwell Varco (NOV) in Houston, Texas, began searching for a strong crane operator training program that could enhance safety and increase awareness at multiple NOV facilities, the company singled out the Overhead Crane Train-the-Trainer course from the Konecranes Training Institute. The program provides a cost-effective approach to training personnel, presenting future trainers with basic to complex information, and equipping them with instructional skills to train employees internally throughout the company.

Instructors of the Konecranes Training Institute have extensive overhead lifting experience, teaching first-hand knowledge about proper crane operation, maintenance, and best practices to improve safety and compliance, productivity, and lifecycle value of equipment. The Institute has trained operators in industries such as steel, utilities, chemical, automotive, foundry, nuclear power, mining, aerospace, paper and waste-to-energy.

soluTionKonecranes provides comprehensive, hands-on trainingIn the fall of 2008, several NOV facilities throughout the country received on-site Train-the-Trainer instruction from the Konecranes Institute. NOV crane operators with varying levels of experience, from as few as two years to as many as 25, participated in the training program.

The instructors put their knowledge in layman’s terms and performed hands-on training to show employees proper rigging techniques, load ratings, and inspections on their own equipment.

“Of all the training programs I reviewed, the Konecranes Institute presented the best course outline, offering the most comprehensive coverage within a good time frame,” says Christy Exley, Health, Safety, Environment (HSE) Manager at NOV in Houston. “The Konecranes Institute offers a true Train-the-Trainer class,” says Exley. “One of its greatest benefits is that the instructor teaches not only overhead crane operation, but the basics of becoming an effective instructor.”

resulTsTraining considered number one accomplishment of the yearVernon Miller, corporate HSE regional manager for NOV, says that NOV employees received the knowledge to move forward safely. “Looking back on the accomplishments my group has made this past year, the Institute training is the number-one selected achievement that was accomplished,” says Miller.

“eVen eMPloYees WiTH More THan 15 Years exPerienCe saiD THeY CaMe aWaY FroM THe Course HaVing learneD soMeTHing neW.”

Christy Exley, Health, Safety, Environment (HSE) Manager, National Oilwell Varco

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a southern Manufacturing CompanyeQuIpmeNt BreaKDoWNs DecreaseD By 60% WIth proper maINteNaNceCHallengeFour to six breakdowns per weekA Southern manufacturing company develops specialized equipment for the oil and gas industry. Each of their 16 25-ton overhead cranes is essential to meeting the high production needs of the facility. The company that had been servicing their cranes tended to focus on problems after they occurred, rather than working to prevent them. As a result, the cranes had an average of four to six breakdowns per week. When the Southern manufacturing company noticed that their cranes were experiencing the same type of breakdown repeatedly, they began to look for a new company to service and maintain their equipment.

soluTionMainMan®inspections and preventive maintenanceThe Southern manufacturing company contacted Konecranes after one of their critical cranes experienced a breakdown during off-peak hours over a weekend. A Konecranes emergency response team was dispatched immediately upon being contacted. After successfully completing the repair, Konecranes proposed an annual inspection contract for each of their cranes using the MAINMAN® inspection program. MAINMAN®is an active preventive maintenance program that uses a multi-point visual inspection to capture data on the condition of over 225 crane components. The data is then used to create a customized plan for scheduled maintenance and repairs. Konecranes currently conducts annual MAINMAN® inspections at the facility and completes scheduled preventive maintenance repairs as needed.

resulTsBreakdowns decreased by 60%, overall decreased costsSince Konecranes began conducting preventive and planned maintenance two years ago, equipment breakdowns at the facility have decreased by over 60%. As a direct result of the MAINMAN® inspection program, maintenance spending and downtime expenses have been dramatically reduced.

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BC Hydro, Mica generating station, British ColumbiatechNoLoGy DeVeLopeD For NucLear INDustry expeDItes uNDerGrouND craNe INstaLLatIoNCHallengespecialized installation needed for underground facilityWhen BC Hydro built their Mica generating station on the Columbia River in 1977, it was designed to hold six generating units. But only four were initially completed, pending a need for more power in the region.

In 2011, the Mica Units 5 and 6 Project was launched to install the two remaining generating units, adding another 1,000 MW of power generating capacity.

To service them, BC Hydro bought two new turbine hall cranes from Konecranes, designed to work in tandem to provide synchronized lifts. At 575 tons each, these massive double girder cranes were the largest ever delivered by Konecranes in North America to date.

Because the entire Mica facility is carved into a mountain, the cranes must operate inside an underground chamber accessed by a 400-foot tunnel. Normal installation inside the underground facility using mobile cranes was not an option, as they would not fit in the limited headroom without removing ceiling supports.

soluTionone-of-a-kind jacking tower installs equipment from belowWorking with Konecranes Nuclear Equipment & Services, Konecranes utilized a state-of- the-art technology developed in 2010 for the nuclear industry to make the challenging install inside

the cavern without removing ceiling supports or, most importantly, disrupting power generation.

This patent-pending jacking tower, the only one of its kind in the world, was delivered by tractor-trailers and assembled inside the cavern to the required height. The jacking tower rests on a base that allows for even load distribution, one large advantage over mobile cranes, whose tires have a very small footprint.

Another advantage is a jib arm that can be used to raise and lower smaller loads. The jacking tower not only has the ability to remove all components from under the crane rather than above, but it also installs the cranes from below.

resulTsequipment installed with minimal production interruptionAccording to Owen Williams, BC Hydro’s project manager, Konecranes jacking tower technology and its ability to install from below was a real advantage in the underground location.

“Konecranes had an elegant way of replacing the existing cranes with new ones which allowed us to install new cranes while having a limited impact on the operating generating station,” he said.

“our generaTing sTaTion ConTinueD To ProViDe aPProxiMaTelY 15% oF BC HYDro’s ToTal PoWer generaTion ouTPuT During THis ProjeCT.”

Owen Williams, Project Manager, BC Hydro

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r.e. ginna nuclear Power Plant, ontario, n.Y.specIaLIzeD craNe eNhaNces saFety throuGh aDVaNceD eNGINeerINGCHallengeHigh-capacity crane needed to handle spent fuelWhen R.E. Ginna Nuclear Power Plant needed a specialized high capacity crane to be able to off-load spent fuel from their fuel pool to dry cask storage, they trusted the expertise of Konecranes.

“We needed to find a partner that could provide us with a significant capacity crane and crane configuration dedicated design. One of the challenges was the fleet cask size – a 125-ton cask – that dictated crane configuration,” says Mark Fitzsimmons, Principal Engineer, Nuclear Engineering Services, from Constellation Energy Nuclear Group.

soluTionCrane developed to meet space, capacity, safety and regulatory requirementsAfter a competitive bid process, Konecranes was selected as a turnkey supplier of a complex single failure proof crane.

During the process of assessing the project, a new challenge was determined: the building structure surrounding the fuel pool was not originally designed to support the weight of a fully loaded 125-ton single failure proof crane that was required to move and load the spent fuel for dry cask storage. Konecranes and Ginna worked closely together during the entire project to make sure the solution would meet the demanding requirements.

Handling spent nuclear fuel is a highly specialized task and requires compliance with strict and comprehensive regulatory requirements of the U.S. Nuclear Regulatory Commission. Konecranes knew that it had the technical knowledge to solve the problem, along with the ability to comply with the stringent requirements of NUREG-0554 and ASME NOG-1 single failure proof crane design criteria.

This was accomplished by designing a hybrid single failure proof crane that was actually installed outside of the crane operating area, but that is able to access the crane operating area by telescoping into the building. This is no small feat considering the crane is rated at 125-tons, is single failure proof and that it reaches into the building to pick up spent nuclear fuel.

resulTsKonecranes continues to provide crane service and support“The crane was installed and delivered on time, but there were some original materials that weren’t as compatible as we would have liked. But Konecranes supported us through the problems, and we ran our first campaign without a hitch.”

Konecranes is now under contract to provide maintenance service for the crane, thereby ensuring that it is properly cared for during its lifetime and that it will perform the key tasks that are necessary to load and handle spent nuclear fuel.

According to Mark, business is growing and they will need high performing cranes as well as support for older cranes on a fleet-wide scale. This could lead to opportunities for more successful joint projects in the future.

“KoneCranes CaMe uP WiTH a neW soluTion BaseD on our CurrenT siTuaTion. iT Was an innoVaTeD iDea, anD THeY PresenTeD a MoDel THaT sHoWeD THe ouTCoMe.”

Mark Fitzsimmons, Nuclear Engineering Services, Principal Engineer

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liberty Paper, inc., Becker, Minn.craNe moDerNIzatIoN Goes oVer aND aBoVe to WIN LoNG-term reLatIoNshIpCHallengeDetermine the current condition and remaining life of a dry end craneLiberty Paper, Inc. (LPI), part of the Liberty Diversified International family, is a state-of-the-art paper mill, located in Becker, Minn. that recycles old corrugated containers into new paper for packaging. The mill manufacturers recycled paper from more than 240,000 tons of corrugated containers each year.

In June 2009, the company turned to Konecranes to complete an end-of-life study on their dry end crane, used primarily in the manufacturing process. The crane had originally been purchased from Konecranes in 1994.

soluTionKonecranes end-of-life study used to scope a modernizationAfter the end-of-life study was complete, LPI received three quotes to upgrade the equipment. Konecranes provided the best added value proposition to LPI, therefore, Konecranes was awarded the job in April 2010. The primary factor was because of the end-of-life study. Konecranes offered an immediate solution that allowed for future expansion plans.

In August 2010, Konecranes installed the modernization to the dry end crane. Konecranes worked around the clock, beginning Monday at 6 a.m. The job was completed by Friday at noon – 24 hours ahead of the deadline. The installation came in on budget and required no downtime from LPI.

resulTsModernization completed on time and on budget, cranes equipped with excess capacity for future expansionBoth hoists were modernized to 30-ton. The hoists were then de-rated to 20-ton cranes, allowing them ample expansion room for future plans.

A Konecranes sales representative explains, “This gives them a lot of flexibility in the future.”

Sixty cycles after the modernization was completed, the hoists were tested for synchronization, which is crucial in the paper process. These critical hoists ran in tandem within one inch of each other

Since the installation, Liberty Papers has signed a service contract with Konecranes. The service contact includes monthly preventive maintenance.

Currently, Konecranes and Liberty Paper are discussing plans to perform these same modernizations to an LPI wet-end crane.

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Weyerhaeuser Paper Mill, savannah, ga.craNe moDerNIzatIoN From KoNecraNes maxImIzes uptIme proDuctIVItyCHallengeCritical crane breaks down frequentlyThe Weyerhaeuser Company, a paper mill located in Savannah, Ga., had an aging crane that broke down on a regular basis. Installed in 1990, the crane was used during regularly scheduled maintenance intervals to move heavy rolls. These press rolls are used to flatten paper pulp.

The pulp, which is wet, is laid over screens to allow water to drain off before moving through the papermaking process. Heavy rolls, 40 tons each, are used to aid in the straining process, applying weight to the raw pulp and forcing water from it. During maintenance, the rolls need to be replaced.

Though used primarily for maintenance operations, the crane is vital, according to Will Tallevast, from Weyerhaeuser, and proper functioning is necessary for safe and efficient shutdowns. The company has 12 scheduled maintenance shutdowns annually.

The unreliable crane was increasing the time spent during scheduled shutdowns by as much as 25 percent. Weyerhaeuser was forced to contract full-time maintenance crews to be on-site 24 hours a day during the maintenance shutdowns. The added costs of the unreliable crane were mounting, says Tallevast.

Safety was also a paramount issue. Moving heavy loads presents specific safety concerns, particularly when the machinery moving the rolls becomes unreliable.

soluTionCustomized crane modernization In 2005, Konecranes, Inc. was initially contracted by Weyerhaeuser to provide on-site maintenance and inspection services as a result of this crane. By 2007, Konecranes recommended Weyerhaeuser consider a modernization to reduce lost time, increase efficiency, and minimize costs. Tallevast agreed—overall efficiency could be maximized with proactive measures.

Konecranes began the modernization process by conducting on-site research on the crane, reviewing maintenance and breakdown records, and estimating the cost. The components were engineered and manufactured specifically for the Weyerhaeuser crane.

The complete modernization, from engineering, manufacturing, shipping and installation, was completed in 16 weeks.

resulTsCrane functions without process-hindering failuresBoth Tallevast and Konecranes agree that maintenance operations at Weyerhaeuser have dramatically improved. There have been no process-hindering crane failures since the modernization project in mid-2007. The crane no longer causes extended maintenance shutdowns, nor does it require the constant maintenance that cost the company hundreds of thousands of dollars in additional costs and lost production. Further, Weyerhaeuser also addressed the air control issues that had long plagued the equipment. Weyerhaeuser is pleased with the work Konecranes did and the work the company continues to do providing inspection services for the facility. In total, the $400,000 project was designed and completed in roughly six months, saving Weyerhaeuser untold dollars in lost revenue and maintenance costs, and reducing the potential for maintenance downtime and safety threats.

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an integrated steel PlantQuaLIty parts eNhaNce saFety aND Decrease DoWNtImeCHallengeWheel flanges break off, causing safety concernOne of the largest integrated steel mills in the world produces flat-rolled steel coils for the automotive industry. The mill uses four electrical overhead traveling cranes to transport 125 tons of metal slabs across a pair of #175 rails in their 1,700 ft. runway yard. The cranes operate 24/7, and the constant movement creates abrasive and adhesive friction that can take a toll on bridge wheel flanges. When the flanges become too thin, the wheels must be replaced.

At the steel mill, bridge wheel flanges started breaking off and falling 40 feet to the work area below. This caused a major safety concern for the mill.

Unfortunately, no one at the mill could determine the cause of the premature thinning of the wheel flanges. When a railway survey firm was brought in to see if a railway misalignment was the problem, the surveyors suggested that they consult a crane company for answers.

soluTionKonecranes 60 Plus™ wheels installedAfter assessing the situation, the P&H® wheel product manager quickly determined that the taper tread wheels were the problem. The solution was to upgrade to flat tread wheels, which have thicker flanges. A set of 60+ test wheels were installed on one of their cranes to see how things would improve. The test wheels did not have any flange wear, while the three cranes with tapered wheels continued to experience problems.

resulTsWheels still in great condition years laterBecause of the overall quality of the wheels, the test wheels were still in nearly new condition three years later. The success of the wheels enhanced safety at the mill and convinced management that Konecranes had made the correct recommendation. Within a few years, the plant’s three other cranes had new flat tread tires installed as well.

P&H® is a registered trademark of Harnischfeger Technologies Inc.

Crane Pro Parts is the parts supply organization of KoneCranes in the U.S.

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a leading steel CompanyINNoVatIVe WheeL DesIGN INcreases LoNGeVItyCHallengeWheel flanges wearing thinOne of the world’s leading steel companies has a plate heat treating plant in the Midwest. The plant heat treats steel plates that range from a quarter inch to several inches thick. The heat treating process makes the steel plates more durable. The steel plant uses cranes during the manufacturing process and to transport the final product.

The wheels on a semi-gantry crane needed to be replaced because the flanges were wearing thin. While the purchasing department wanted to purchase wheels based on price, the area manager wanted wheels that would last a long time.

soluTionKonecranes and Crane Pro Parts, the sole Provider of 60 Plus ™ wheelsWith over 40 years of experience in the steel industry, the area manager understands the value of having great wheels. During his time in the business, he has tried several other wheels and was not satisfied with how frequently they needed to be replaced. He wanted to get 60 Plus™ induction hardened wheels because they are the industry standard for longevity.

Konecranes 60 Plus™ wheels have a hardened exterior flange profile and a softer flange core which increases its toughness. The uniform hard profile on the flange exterior surface causes less friction upon contact between the wheel flange and the side-of-rail head, decreasing flange and rail wear rates and increasing the life of the wheel.

The area manager called Konecranes for a budgetary quote for the set of wheels. The company policy is to receive three quotes, so two other crane companies were consulted as well. Instead of leaving the choice up to chance, the area manager explained to the purchasing department that it is necessary to select the wheels with the best quality. He firmly believed that the 60 Plus™ wheels had the best value overall. In the end, he justified the purchase of the 60 Plus™ wheels.

resulTsPeace of mind with a good buying decision—Konecranes 60 Plus™ WheelsFive of the 60 Plus™ hardened wheels have been purchased and were delivered to the plant in July. The area manager knows that this was a good economic choice for the company.

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Crane Pro Parts is the parts supply organization of KoneCranes in the U.S.

johannessen Trading Company in Commerce, Calif. expert KNoWLeDGe aND Fast, eFFIcIeNt repaIr saVeD customer oVer $20,000 usDCHallengeCrane vendor unable to identify part–suggests purchasing a new craneJohannessen Trading Company in Commerce, Calif. distributes steel and construction products. Cranes are used to load steel for deliveries and to stock steel in the facility. A competitor of Konecranes handles the crane work for the facility.

When a hoist load brake needed to be repaired, the competing crane company suggested and quoted a new hoist and trolley to the customer. The crane company was unable to identify any of the crane components or prices and they thought the parts for the hoist were now obsolete. Johannessen Trading needed an immediate solution. Switching the hoist and trolley system would require a long lead time. The several weeks of down time to switch to a new system would be expensive. Johannessen Trading Co. called Konecranes for a second opinion.

soluTionKonecranes quickly identified and replaced the partJohannessen Trading Co. asked Konecranes to look at the crane to see if they could identify the correct part that they needed. Though a serial number could not be found on the crane, Konecranes knew the make and model from previous experience with that type of crane. Using that information, Crane Pro Parts was able to identify the correct part numbers and provide pricing information.

Konecranes was then able to propose a repair for the hoist load brake. The customer was impressed by how quickly the part was identified but were even more impressed that Konecranes could have their crane up and running in only a couple of weeks. Their vendor could not do this for them, which is why they chose Konecranes for this project.

resulTsThe customer saved over $20,000 usDTwo weeks later, the load brake was installed without issue. The crane was tested and put back into production. Konecranes saved Johannessen Trading Company over $20,000 USD because they did not need to purchase a new hoist and trolley system. The repair also saved several weeks in unnecessary downtime.

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Crane Pro Parts is the parts supply organization of KoneCranes in the U.S.

eMj Metals, Houston, TexaspreVeNtIVe maINteNaNce cuts BreaKDoWNs IN haLF WhILe eNhaNcING saFety aND proDuctIVItyCHallengeimproper repairs lead to frequent breakdownsKonecranes began working with steel service center EMJ Metals in 2008 when new management began looking for a more satisfactory crane service team. Konecranes assured Manager of Plant Operations Ken Herlacher that a proactive, preventive maintenance plan could save the company money.

A previous provider had been maintaining the equipment using the “lowest possible cost” approach. As a result, most of EMJ’s cranes had improper repairs and incorrect parts. A semi-gantry was a prime example; when Konecranes first inspected it, all four of its wheels were different sizes and the crane could not track properly. Breakdowns on EMJ’s cranes were common.

soluTionKonecranes uses a proactive approach to crane maintenanceKonecranes began performing repairs on EMJ’s 10 overhead, gantry and jib cranes, using correct parts and procedures. While the customer was accustomed to inexpensive, “BAND-AID®-style” repairs, Konecranes began fixing the problems correctly. This situation continued from August 2008 through the end of 2009, when the relationship began to evolve.

Instead of questioning each repair and estimate, good communication between the two companies assured EMJ that the repairs Konecranes recommended were justified. When EMJ needed a new 15-ton crane and a runway extension for a 48,000 square foot expansion, Konecranes won the order, installing 240 feet of runway and an advanced Konecranes CXT crane.

resulTsKonecranes MainMan®program cuts emergency breakdowns in half, annual Business review used for long-term capital planningEMJ now uses Konecranes Annual Business Review to plan its maintenance budget for the upcoming year and Konecranes Job Safety Analysis procedure has become a requirement for EMJ’s other vendors. Two of the older cranes, rated 10-tons and 15-tons, are scheduled for replacement with Konecranes CXT cranes.

From 2008 to 2010, Konecranes responded to approximately 45 emergency service calls at EMJ when the customer had a load suspended or was unable to pick up a load. After a year and a half of inspections and preventive maintenance with Konecranes MAINMAN®program and correct repairs, that number has been cut in half. Now, the customer is able to budget for capital improvements rather than repairs.

“i HaVe 100% ConFiDenCe in KoneCranes. our CosT oF rePairs Has gone DoWn suBsTanTiallY. i aM also aPPreCiaTiVe THaT THeY sHare THe saMe saFeTY goals THaT We Do.”

Ken Herlacher, Manager of Plant Operations

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a leading steel Manufacturerexpert KNoWLeDGe eNhaNceD saFety WhILe INcreasING part QuaLItyCHallengeunpredictable machinery control, a concern for safety and productivityA leading steel manufacturer in the Midwest specializes in hot and cold rolled steel, carbon steel melting, and steel castings. Electronic roll grinders are used to grind the large steel rolls that form, press and finish hot and cold rolled steel. Because of the extreme amount of wear-and-tear involved with forming their rolled steel products, the steel rolls need to be replaced a few times every day. Therefore, the steel rolls and the machines that grind them are vital to steel mill’s productivity.

The steel mill’s CNC roll grinder was experiencing erratic malfunctions. The operator could not trust that the machine would consistently perform the work required to the dimensions programmed. When the grinding axis functioned unpredictably, the operator did not have control over how close the grinding wheel would come toward the product. Finely controlled movements are needed in order to consistently grind accurate parts. In addition, this malfunction raised safety concerns. The large grinding wheel could fail catastrophically upon impact with the part, presenting risk of serious harm to the operator.

The internal maintenance team and other service companies made several attempts to fix the problem, but were unsuccessful. Even the top service people from the original equipment manufacturer and the control manufacturer were unable to resolve the problem as well.

soluTionKonecranes MTs restores machine beyond original capabilitiesKonecranes Machine Tool Service (MTS) was able to determine the root cause of the problem within three hours. They also implemented a

temporary solution that allowed the machine to run in a reliable manner until the scheduled permanent repair could be completed.

Once the machine was repaired, it achieved the best repetitive performance of its lifetime. The safety concern of the inconsistent behavior of the grinding wheel was eliminated. While on site, Konecranes MTS repaired several other features, restoring the machine to its full capabilities.

resulTsMachine now performs in a reliable mannerThe operator could now trust that the machine would consistently perform the work required. The steel mill experienced a remarkable difference in the dependability of the machine. Based on the success of this project, Konecranes will perform a control retrofit on the roll grinder with state-of-the-art technology which will make the grinder easier to operate, service and support.

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a steel Manufacturing PlantcraNe pro parts proVIDes exceptIoNaL customer support aFter the saLeCHallengeBottom block incompatible with attachments, threatening safetyA steel manufacturing plant, located in the southern United States, produces 1.4 million tons of hot-rolled steel coils per year. The company’s manufacturing facility features a twin-shell DC electric arc furnace, a ladle metallurgy facility, a thin-slab continuous caster and a six-stand hot finishing mill. The company utilizes overhead cranes in their manufacturing process.

The steel manufacturing plant purchased a rotating bottom block for their overhead crane located in the Roll Shop, in order to enhance safety and increase productivity. After the block was installed, they realized that the hook was not compatible with the lifter bails used to handle back up rolls to support the rolling mill. Maintaining a safe working environment is the first priority at the steel manufacturing plant, so this was a major concern.

soluTionBlock rebuilt, with temporary replacement to maintain productionCrane Pro Parts was on site when the customer noticed the problem and responded immediately with a solution. The new block was removed from service and temporarily replaced with the original unit. The block was sent to a Konecranes preferred machine shop and customized to fit the customer’s roll lifters.

The block was reassembled and returned to the customer within a few weeks, then reinstalled with support from the Konecranes Service group.

resulTsrebuilt bottom block returned to service with enhanced safety and productivityThe steel manufacturing plant was able to enhance the safety and productivity of the roll handling crane because of the rotating bottom block that Konecranes provided. The customer is happy that Konecranes was able to provide a solution to the situation and offer support for the products sold. Crane Pro Parts has provided parts proposals for OEM cranes on hand in the plant for future spares requirements.

Crane Pro Parts is the parts supply organization of KoneCranes in the U.S.

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Crane serViCeMainMan®

Alaskan Copper & Brass ................ 22An Integrated Aluminum Facility ...... 25APM Terminals ............................... 30A Southern Manufacturing Co. ........ 46EMJ Metals ................................... 62

MoDernizaTion

NASA’s Glenn Research Center ......... 8Liberty Paper, Inc. .......................... 54Weyerhaeuser Paper Mill ................ 56

PreVenTiVe MainTenanCe

A Midwest Diesel Engine Manufacturer ............................. 15

A Weld Tool Center ..........................16An Integrated Aluminum Facility ...... 25Union Pacific Railroad .................... 33A Midwest Locomotive Shop ........... 34A Southern Manufacturing

Company ................................... 46EMJ Metals ................................... 62

raDio ConTrols

Novelis ...........................................24

HeaVY DuTY CranesResort Municipality of Whistler ....... 12BC Hydro, Mica Generating Station ... 48

MaCHine Tool serViCeTeledyne Technologies, Inc. .............. 7A Leading Aerostructure

Manufacturer ..............................10

Link-Belt Construction Equipment Company, Inc. ............................ 18

A Leading Construction Equipment Manufacturer ............................. 19

A Leading Construction Equipment Manufacturer ............................. 21

An Underground Mining Equipment Manufacturer ..............................37

A Mining Machinery Company ......... 38A Mining Equipment Manufacturer .. 39Elevating Boats, LLC ...................... 43A Leading Steel Manufacturer ........ 64

nuClearR.E. Ginna Nuclear Power Plant ...... 50

ParTsAn Integrated Steel Plant ............... 59Johannessen Trading Company....... 60A Leading Steel Company ............... 61A Steel Manufacturing Plant ........... 66

PorTal serViCeAPM Terminals ............................... 30

sTanDarD DuTY CranesBrithinee Electric ........................... 11Bauer Manufacturing, Inc. ...............17U.S. Concrete ................................ 20Westfield Industries ....................... 26Limbach Company ......................... 28

TrainingA Leading Mining Manufacturer ...... 40National Oilwell Varco .................... 44

INDex

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